Plastic system and method of porous bioimplant having a unified connector

ABSTRACT

The present ivention relates to a system and a method of manufacturing a porous bio-implant having a connecting member integrally formed therewith, and more particularly, to a system and a method of manufacturing a porous bio-implant in which a connecting member is integrally formed by sintering a metal powder by a high voltage instant discharge in the state that the connecting member is inserted in a pyrex tube and then the metal powder is put in the pyrex tube. A system of manufacturing a porous bio-implant having a connecting member formed integally therewith includes a power supply supplying a low voltage; a voltage booster for boosting the low voltage supplied from the power supply to a high voltage; a condenser charging the high voltage boosted by the voltage booster through a switch; a vacuum switch for istantaneously discharging the high voltage charged in the condenser; and a bio-implant manufacturing apparatus for manufacturing a bio-implant by the high voltage discharged instantaneously from the vacuum switch.

TECHNICAL FIELD

[0001] The present invention relates to a system and a method ofmanufacturing a porous bio-implant having a connecting member integrallyformed therewith, and more particularly, to a system and a method ofmanufacturing a porous bio-implant in which a connecting member isintegrally formed by sintering a metal powder by a high voltage instantdischarge in the state that the connecting member is inserted into apyrex tube and then the metal powder is put in the pyrex tube.

BACKGROUND ART

[0002] A conventional non-porous implant of a screw type and aconventional porous implant manufactured by a high temperature sinteringare described with reference to FIGS. 1 and 2.

[0003]FIG. 1 is a perspective view illustrating a porous screw-typeimplant manufactured by a mechanical processing according to aconventional art. FIG. 2 is a front view illustrating an implantmanufactured by a high temperature sintering according to a conventionalart.

[0004] A screw-type implant 10 is manufactured by a mechanicalprocessing using a milling machine 20. Thus, a processing is verydifficult, and a lengthy processing time is required. Also, due to aformation of an oxide film by a secondary processing, a manufacturingcost is high. In addition, a bonding power is poor due to a smallcontacting area to a bone or a fibrous tissue when implanted into bodytissue, and therefore the implant 10 can be easily removed from the bodytissue. In the case that a large-sized implant is implanted into bodytissue so as to overcome this problem, a treatment time period becomeslengthy, and the implant can locally be implanted into only body tissuehaving a relatively high bone density and having a large size.

[0005] In effort to overcome these problems, a method of manufacturing aporous implant by sintering metal powders at a high temperature has beenintroduced.

[0006] As shown in FIG. 2, metal powders 30 are put in a mold 40 andsintered at a high temperature during a long time period. Or, as shownin FIG. 2B, after putting the metal powers in the mold 40, a bar 50 isinserted to pass through a central portion of the metal powders 30, andthe metal powders 30 are sintered at a high temperature during a longtime period.

[0007] However, the method of FIG. 2 has a problem in that a metalinherent nature variation, a low durability, a surface variation, alengthy sintering, and a high production cost.

[0008] Accordingly, there is a need for a technique of manufacturing anew implant in which a production cost is low, a contacting area betweenthe implant and the bone is improved, a bonding power between theimplant and the bone, a durability is high, a life span is lengthy, atreatment period is short, and a compression strength can be adjusted byadjusting a size of the implant.

DISCLOSURE OF INVENTION

[0009] To overcome the problems described above, preferred embodimentsof the present invention provide a system and a method of manufacturinga porous bio-implant having a connecting member formed integrallytherewith in which does not require subsequent processes because a metalpower in a pyrex tube is sintered by a high temperature instantdischarge and so attached to the connecting member.

[0010] It is another object of the present invention to provide a systemand a method of manufacturing a porous bio-implant having a connectingmember formed integrally therewith which can adjust a compressionstrength according to a location of respective teeth by adjusting a sizeof the connecting member.

[0011] The system of manufacturing a porous bio-implant having aconnecting member formed integrally therewith includes a power supplyfor supplying a low voltage; a voltage booster for boosting the lowvoltage supplied from the power supply to a high voltage; a condensercharging the high voltage boosted by the voltage booster through aswitch; a vacuum switch for instantaneously discharging the high voltagecharged in the condenser; and a bio-implant manufacturing apparatus formanufacturing a bio-implant by the high voltage dischargedinstantaneously from the vacuum switch.

[0012] The bio-implant manufacturing apparatus includes a hollow pyrextube; the connecting member inserted into the pyrex tube; a metal powderinserted in an inner space of the pyrex tube under the connectingmember; an upper electrode inserted into an upper opening of the pyrextube and rested on an upper surface of the connecting member; and alower electrode inserted into a lower opening of the pyrex tube topressurize the metal powder.

[0013] The connecting member includes a connecting member main; a headerportion integrally formed on an upper central portion of the connectingmember main, and a screw hole formed in a predetermined depth under theheader portion.

[0014] The lower electrode has a concave groove formed in apredetermiend depth. The bio-implant manufactured by the bio-implantmanufacturing apparatus is integrally formed with the connecting memberby sintering the metal powder by combination of a pinch pressure and aheat energy, and has a porous layer on an outer surface thereof.

[0015] A surface roughness of the bio-implant manufactured by thebio-implant manufacturing apparatus is determined by adjusting a size ofthe metal powder. A compression strength of the bio-implant manufacturedby the bio-implant manufacturing apparatus is determined by adjusting asize of the connecting member.

[0016] A method of manufacturing a porous bio-implant having aconnecting member formed integrally therewith includes the steps of:inserting the connecting member into a pyrex tube through an upperopening of the pyrex tube; inserting a metal powder into the pyrex tubethrough a lower opening of the pyrex tube; inserting an upper electrodethrough the upper opening of the pyrex tube and resting the upperelectrode on the upper surface of the connecting member, and inserting alower electrode through the lower opening of the pyrex tube; supplying alow voltage from a power supply connected to the upper and lowerelectrodes; boosting the low voltage to a high voltage by a voltagebooster; charging the high voltage boosted by the voltage booster in thecondenser through a switch; discharging the high voltage charged in thecondenser instantaneously through the vacuum switch; and sintering themetal powder in the pyrex tube, thereby forming a porous bio-implantintegrally with the connecting member.

BRIEF DESCRIPTION OF DRAWINGS

[0017] For a more complete under supporting of the present invention andthe advantages thereof, reference is now made to the followingdescriptions taken in conjunction with the accompanying drawings, inwhich like reference numerals denote like parts, and in which:

[0018]FIG. 1 is a perspective view illustrating a screw-type implantmanufactured by a mechanical processing according to a conventional art;

[0019]FIG. 2 is a front view a porous implant manufactured by a hightemperature sintering according to a conventional art;

[0020]FIG. 3 is a circuit diagram a porous bio-implant manufacturingsystem according to one embodiment of the present invention;

[0021]FIG. 4 shows the porous bio-implant manufacturing apparatusaccording to the present invention

[0022]FIG. 5 is a block diagram illustrating the porous bio-implantmanufacturing system according to one embodiment of the presentinvention;

[0023]FIG. 6 is a cross-sectional view illustrating various pyrex tubesaccording to one embodiment of the present invention;

[0024]FIG. 7 is a front view illustrating a porous bio-implantmanufactured according to one embodiment of the present invention;

[0025]FIG. 8 is a cross-sectional view illustrating the porousbio-implant manufactured according to one embodiment of the presentinvention;

[0026]FIG. 9 is a front view illustrating a porous layer of the porousbio-implant manufactured to one embodiment of the present invention;

[0027]FIG. 10 is a front view illustrating pores of the porous layer ofthe porous bio-implant manufactured to one embodiment of the presentinvention;

[0028]FIG. 11 is a flow chart illustrating a process of manufacturing aporous bio-implant according to one embodiment of the present invention;

[0029]FIG. 12 is a circuit diagram illustrating a porous bio-implantmanufacturing system according to another embodiment of the presentinvention;

[0030]FIG. 13 is a cross-sectional view illustrating a porousbio-implant manufactured according to another embodiment of the presentinvention; and

[0031]FIG. 14 is a flow chart illustrating a process of manufacturing aporous bio-implant according to another embodiment of the presentinvention.

BEST MODE FOR CARRYING OUT THE INVENTION

[0032] Reference will now be made in detail to preferred embodiments ofthe present invention, example of which is illustrated in theaccompanying drawings. Like reference numerals denote like parts.

[0033]FIG. 3 is a circuit diagram a porous bio-implant manufacturingsystem according to one embodiment of the present invention. FIG. 4shows the porous bio-implant manufacturing apparatus according to thepresent invention. FIG. 5 is a block diagram illustrating the porousbio-implant manufacturing system according to one embodiment of thepresent invention. FIG. 6 is a cross-sectional view illustrating variouspyrex tubes according to one embodiment of the present invention. FIG. 7is a front view illustrating a porous bio-implant manufactured accordingto one embodiment of the present invention. FIG. 8 is a cross-sectionalview illustrating the porous bio-implant manufactured according to oneembodiment of the present invention. FIG. 9 is a front view illustratinga porous layer of the porous bio-implant manufactured to one embodimentof the present invention. FIG. 10 is a front view illustrating pores ofthe porous layer of the porous bio-implant manufactured to oneembodiment of the present invention.

[0034] The porous bio-implant manufacturing system includes a powersupply 60, a voltage booster 70, a first switch 80, a condenser 90, avacuum switch 100, and a porous bio-implant manufacturing apparatus 110.

[0035] The porous bio-implant manufacturing apparatus 110 includes apyrex tube 112, 112 a or 112 b to which a metal powder 111, 111 a or 111b, upper and lower electrodes 113, 113 a or 113 b which is inserted intoand attached to the pyrex tube 112, 112 a or 112 b, upper and lowerelectrode holders 114, upper and lower suspension members 115, and amain support 116.

[0036] The pyrex tube 112, 112 a or 112 b are hollow, and the metalpowder 111, 111 a or 111 b is put on the middle of the pyrex tube 112,112 a or 112 b. The pyrex tube 112, 112 a or 112 b is preferably made ofquartz, and can have various shapes.

[0037] The upper and lower electrodes 113, 113 a or 113 b are insertedinto and attached to both upper and lower openings of the pyrex tube112, 112 a or 112 b. The upper and lower electrode holders 114 firmlyhold the upper and lower electrodes 113, 113 a or 113 b. The upper andlower electrodes 113, 113 a or 113 b are preferably made of copper orbrass.

[0038] The upper and lower suspension members 115 connect the upper andlower electrode holders 114 to the main support 116, respectively.

[0039] Operation of the porous bio-implant manufacturing system isdescribed below.

[0040] A low voltage of 100 volts or 200 volts is supplied from thepower supply 60. The voltage booster 70 boosts the low voltage to a highvoltage of 1000 volts to 5000 volts and preferably to a high voltage of2500 volts. The high voltage passes through the first switch 80 andcharges the condenser 90. The high voltage charged in the condenser 90are discharged instantaneously through the vacuum switch 100 to sinterthe metal powder 111, 111 a or 111 b in the pyrex tube 112, 112 a or 112b, thereby forming a porous bio-implant according to one embodiment ofthe present invention.

[0041] The porous bio-implant has an inner solid tissue and an outerporous layer. The inner solid tissue increases a durability of thebio-implant. The outer porous layer b allows for bone growth or fibroustissue growth and malleable to allow it to conform to various shapes,thereby providing a strong, solid support when fixed to the bone andincreasing a life span of the bio-implant. A pore size of the porouslayer b is preferably in a range between 100 μm and 200 μm.

[0042] In greater detail, the metal powder 111, 111 a or 111 b in thepyrex tube 112, 112 a or 112 b is sintered by an electro dischargesintering (EDS) technique to forming pores on an outer surface of theporous bio-implant and form a solid core on an inner portion of theporous bio-implant. This mechanism is performed by combining a pinchpressure required to transform and squeeze the metal powder 111, 111 aor 111 b and a heat energy required to weld the metal powder 111, 111 aor 111 b.

[0043] A relationship between the heat energy and the solid core size isanalyzed using experimental data as follows: a size of the solid core is2.24 μm when a heat energy is 977 [J], and a size of the solid core is2.47 μm when a heat energy is 1,340 [J]. It is understood that a size ofthe solid core is proportion to a heat energy.

[0044] A surface roughness of the porous bio-implant depends on a sizeof the metal powder 111, 111 a or 111 b. The solid core, a processingsize, a processing rate, and a durability can be controlled by varying acapacity of the condenser 90, that is, varying an amount of an electricenergy charged in the condenser 90.

[0045]FIG. 11 is a flow chart illustrating a process of manufacturing aporous bio-implant according to one embodiment of the present invention.

[0046] First, the metal powder 111, 111 a or 111 b is put in the middleof the pyrex tube 112, 112 a or 112 b (step S100). The upper and lowerelectrodes 113, 113 a or 113 b are inserted into and attached to bothupper and lower openings of the pyrex tube 112, 112 a or 112 b (stepS200).

[0047] A low voltage of 100 volts or 200 volts is supplied from thepower supply 60 (step S300). The voltage booster 70 boosts the lowvoltage to a high voltage of 1000 volts to 5000 volts and preferably toa high voltage of 2500 volts (step S400). The high voltage passesthrough the first switch 80 and charges the condenser 90 (step S500).

[0048] The high voltage charged in the condenser 90 are dischargedinstantaneously through the vacuum switch 100 (step S600) to sinter themetal powder 111, 111 a or 111 b in the pyrex tube 112, 112 a or 112 b,thereby forming a porous bio-implant (step S700).

[0049]FIG. 12 is a circuit diagram illustrating a porous bio-implantmanufacturing system according to another embodiment of the presentinvention. FIG. 13 is a cross-sectional view illustrating a porousbio-implant manufactured according to another embodiment of the presentinvention.

[0050] The porous bio-implant manufacturing system according to anotherembodiment of the present invention includes a power supply 120, avoltage booster 130, a first switch 140, a condenser 150, a vacuumswitch 160, and a porous bio-implant manufacturing apparatus 170.

[0051] A low voltage of 100 volts or 200 volts is supplied from thepower supply 120. The voltage booster 130 boosts the low voltage to ahigh voltage of 1000 volts to 5000 volts and preferably to a highvoltage of 2500 volts. The high voltage passes through the first switch140 and charges the condenser 150. The high voltage charged in thecondenser 150 are discharged instantaneously through the vacuum switch160.

[0052] The porous bio-implant manufacturing unit 170 includes a pyrextube 172, upper and lower electrodes 173 a and 173 b, and a connectingmember 174.

[0053] The pyrex tube 172 is hollow and is preferably made of quartz.The pyrex tube 172 can have various shapes. The upper and lowerelectrodes 173 a and 173 b are made of copper or brass.

[0054] The connecting member 174 includes a connecting member main 174a, a header portion 174 b and a screw hole 174 c. The connecting membermain 174 a preferably has a cross-section of a cross shape. The headerportion 174 b is formed on an upper central portion of the connectingmember main 174 a and preferably has a hexagon. The screw hole 174 c isformed to a predetermined depth under the header portion 174 b.Preferably, a distance between opposite sides of the header portion 174b is 2.7 mm, and a diameter of the screw hole 174 c is 2.0 mm. Theconnecting member 174 can have various shapes.

[0055] The connecting member 174 is inserted into the pyrex tube 172through an upper opening of the pyrex tube 172. A metal powder 171 isinserted into the middle of the pyrex tube 172 through a lower openingof the pyrex tube 172.

[0056] The upper electrode 173 a is inserted through the upper openingof the pyrex tube 172 and rested on the upper surface of the connectingmember 174. The lower electrode 173 b having a concave surface isinserted through the lower opening of the pyrex tube 172. The upper andlower electrodes 173 a and 173 b are preferably made of Cu, brass, Gr,Ag—W, Cu—W, or Pt. The upper surface of the lower electrode 173 b canhave various shapes other than a concave shape.

[0057] Operation of the porous bio-implant manufacturing system isdescribed below.

[0058] A low voltage of 100 volts or 200 volts is supplied from thepower supply 130. The voltage booster 140 boosts the low voltage to ahigh voltage of 1000 volts to 5000 volts and preferably to a highvoltage of 2500 volts. The high voltage passes through the first switch140 and charges the condenser 150.

[0059] The high voltage charged in the condenser 150 are dischargedinstantaneously through the vacuum switch 160 to sinter the metal powder171 in the pyrex tube 172, thereby forming a porous bio-implantintegrally with the connecting member 174.

[0060] The porous bio-implant has an inner solid tissue and an outerporous layer. The inner solid tissue increases a durability of thebio-implant. The outer porous layer allows for bone growth or fibroustissue growth and malleable to allow it to conform to various shapes,thereby providing a strong, solid support when fixed to the bone andincreasing a life span of the bio-implant. A pore size of the porouslayer is preferably in a range between 100 μm and 200 μm. A surfaceroughness of the porous bio-implant depends on a size of the metalpowder 171. A compression strength of the porous bio-implant isdetermined by a size of the connecting member 174.

[0061] The porous bio-implant having the connecting member 174 formedintegrally therewith is manufactured by combining a pinch pressurerequired to transform and squeeze the metal powder 171 and a heat energyrequired to weld the metal powder 171.

[0062]FIG. 14 is a flow chart illustrating a process of manufacturingthe porous bio-implant according to another embodiment of the presentinvention.

[0063] The connecting member 174 is inserted into the pyrex tube 172through the upper opening of the pyrex tube 172 (step S100 a). A metalpowder 171 is inserted into the middle of the pyrex tube 172 through thelower opening of the pyrex tube 172 (step S200 a).

[0064] The upper electrode 173 a is inserted through the upper openingof the pyrex tube 172 and rested on the upper surface of the connectingmember 174. The lower electrode 173 b having a concave surface isinserted through the lower opening of the pyrex tube 172 (step S300 a).

[0065] A low voltage of 100 volts or 200 volts is supplied from thepower supply 120 (step S400 a). The voltage booster 130 boosts the lowvoltage to a high voltage of 1000 volts to 5000 volts and preferably toa high voltage of 2500 volts (step S500 a). The high voltage is chargedthe condenser 150 through the first switch 140 (step S600 a).

[0066] The high voltage charged in the condenser 150 is dischargedinstantaneously through the vacuum switch 160 (step S700 a) to sinterthe metal powder 171 in the pyrex tube 172, thereby forming a porousbio-implant integrally with the connecting member 174 (step S800 a).

INDUSTRIAL APPLICABILITY

[0067] As described herein before, the porous bio-implant has thefollowing advantages. Since the porous bio-implant is integrally formedwith the connecting member, a subsequent manufacturing process is notrequired, leading a simplified manufacturing process, a high throughput,and a high processing precision. A compression strength of the porousbio-implant can be adjusted by adjusting a size of the connectingmember.

[0068] While the invention has been particularly shown and describedwith reference to preferred embodiments thereof, it will be understoodby those skilled in the art that the foregoing and other changes in formand details may be made therein without departing from the spirit andscope of the invention.

What is claimed is:
 1. A system of manufacturing a porous bio-implanthaving a connecting member formed integrally therewith, comprising: apower supply 120 for supplying a low voltage; a voltage booster 130 forboosting the low voltage supplied from the power supply 120 to a highvoltage; a condenser 150 charging the high voltage boosted by thevoltage booster 130 through a switch; a vacuum switch 160 forinstanteneously discharging the high voltage charged in the condenser150; and a bio-implant manufacturing apparatus 170 for manufacturing abio-implant by the high voltage discharged instantaneously from thevacuum switch
 160. 2. The system of claim 1, wherein the bio-implantmanufacturing apparatus 170 includes a hollow pyrex tube 172; theconnecting member 174 inserted into the pyrex tube 172; a metal powder171 inserted in an inner space of the pyrex tube 172 under theconnecting member 174; an upper electrode 173 a inserted into an upperopening of the pyrex tube 172 and rested on an upper surface of theconnecting member 174; and a lower electrode 173 b inserted into a loweropening of the pyrex tube 172 to pressurize the metal powder
 171. 3. Thesystem of claim 2, wherein the connecting member 174 includes aconnecting member main 174; a header portion 174 b integrally formed onan upper central portion of the connecting member main 174 a; and ascrew hole formed in a predetermined depth under the header portion 174b.
 4. The system of claim 2, wherein the lower electrode 173 b has aconcave groove formed in a predetermiend depth.
 5. The system of claim2, wherein the bio-implant manufactured by the bio-implant manufacturingapparatus 170 is integrally formed with the connecting member 174 bysintering the metal powder 171 by combination of a pinch pressure and aheat energy, and has a porous layer on an outer surface thereof.
 6. Thesystem of claim 2, wherein a surface roughness of the bio-implantmanufactured by the bio-implant manufacturing apparatus 170 isdetermined by adjusting a size of the metal powder
 171. 7. The system ofclaim 2, wherein a compression strength of the bio-implant manufacturedby the bio-implant manufacturing apparatus 170 is determined byadjusting a size of the connecting member
 174. 8. A method ofmanufacturing a porous bio-implant having a connecting member formedintegrally therewith, comprising the steps of: inserting the connectingmember 174 into a pyrex tube 172 through an upper opening of the pyrextube 172 (step S100 a); inserting a metal powder 171 into the pyrex tube172 through a lower opening of the pyrex tube 172 (step S200 a);inserting an upper electrode 173 a through the upper opening of thepyrex tube 172 and resting the upper electrode 173 a on the uppersurface of the connecting member 174, and inserting a lower electrode173 b through the lower opening of the pyrex tube 172 (step S300 a);supplying a low voltage from a power supply 120 connected to the upperand lower electrodes 173 a and 173 b (step S400 a); boosting the lowvoltage to a high voltage by a voltage booster 130 (step S500 a);charging the high voltage boosted by the voltage booster 130 in thecondenser 90 through a switch (step S600 a); discharging the highvoltage charged in the condenser 150 instantaneously through the vacuumswitch 160 (step S700 a); and sintering the metal powder 171 in thepyrex tube 172, thereby forming a porous bio-implant integrally with theconnecting member 174 (step S800 a).